Optoma HD33, Service Manual

Page 1: ...SERVICE MANUAL Prepared Check Approved Date Revise Version Description 2011 08 17 V1 0 Initial Issue HD33 Copyright Aug 2011 All Rights Reserved Mina Amy ...

Page 2: ...tomers will appreciate the service that you offer them This manual is for technicians and people who have an electronic background Please send the product back to the distributor for repairing and do not attempt to do anything that is complex or not mentioned in the troubleshooting Notice The information found in this manual is subject to change without prior notice Any subsequent changes made to ...

Page 3: ... Usage Hour 2 7 Repair Action 2 8 Chapter 3 Troubleshooting LED Lighting Message For Projector 3 1 Main Procedure 3 2 Chapter 4 Function Test Alignment Procedure Test Equipment Needed 4 1 Test Condition 4 1 I O Port Test 4 2 Run In Test 4 8 Test Inspection Procedure 4 9 ADC Calibration 4 10 Restore Blower Speed 4 11 Chapter 5 Firmware Upgrade Section 1 Pixelworks for FW Upgrade USB 5 1 Equipment N...

Page 4: ...rade RS232 5 6 Equipment Needed 5 6 Firmware Upgrade Procedure 5 7 Section 3 8051 FW Upgrade 5 9 Equipment Needed 5 9 8051 Firmware Upgrade Procedure 5 10 Check 8051 FW version 5 11 Chapter 6 EDID Upgrade EDID Upgrade Procedure 6 1 Appendix A Exploded Image I Appendix B Serial Number Definition I PCBA Code Definition II III ...

Page 5: ...ival Rate ECO Mode 4000 Hours Typical 230W 50 Survival Rate 8 Lamp 280W Lamp Osram E20 8 9 DMD Chip Number of active dots 0 65 1080P Number of active dots 1080P 10 Color wheel 6 segments R62G64B54R62G64B54 11 System controller TI DDP 3021 12 Video compatibility NTSC M 3 58MHz 4 43MHz PAL B D G H I M N 4 43MHz SECAM B D G K K1 L 4 25 4 4MHz SDTV 480i p 576i p HDTV 720p 50 60Hz 1080i 50 60Hz 1080p 2...

Page 6: ...GA 640 x 480 37 9 72 8 VGA 640 x 480 37 5 75 VGA 640 x 480 43 3 85 SVGA 800 x 600 35 2 56 3 SVGA 800 x 600 37 9 60 3 SVGA 800 x 600 46 9 75 SVGA 800 x 600 48 1 72 2 SVGA 800 x 600 53 7 85 1 SVGA 832 x 624 75 XGA 1024 x 768 48 4 60 XGA 1024 x 768 56 5 70 1 XGA 1024 x 768 60 75 XGA 1024 x 768 68 7 85 XGA 1024 x 768 68 7 120 XGA 1152 x 864 75 HD720 1280 x 720 50 HD720 1280 x 720 60 HD720 1280 x 720 1...

Page 7: ...80 1920 x 1080 50 HD1080 1920 x 1080 60 WUXGA 1920 x 1200 60 HDTV 1920 x 1080i 50 HDTV 1920 x 1080i 60 HDTV 1920 x 1080p 24 HDTV 1920 x 1080p 50 HDTV 1920 x 1080p 60 HDTV 1280 x 720 45 60 HDTV 1280 x 720p 50 HDTV 1280 x 720p 60 SDTV 720 x 576 31 3 50 SDTV 720 x 576i 50 SDTV 720 x 576p 50 SDTV 720 x 480 31 5 60 SDTV 720 x 480i 60 SDTV 720 x 480p 60 Note If the Computer Compatibility supportive sign...

Page 8: ...Screw Bit 107 3 Screw Bit 107 4 Hex Sleeves 5 mm 5 Tweezers 6 Projector Before you start This process is protective level II Operators should wear electrostatic chains Note If you need to replace the main board you have to record the lamp usage hour Some related contents please refer to common SM chapter 2 ...

Page 9: ...over Module 2 1 2 Disassemble Main Board 1 Unscrew 11 screws as red circle 2 Unplug 9 connector as green square 1 Unscrew 6 screws as red circle from the Bottom Cover 2 Press two sides of the projector and push them as the blue arrow 3 Remove the Top Cover Module ...

Page 10: ...HD33 Confidential 2 3 Unscrew 6 screws as blue circle 4 Unplug 1 connector as yellow square 5 Disassemble Main Board Scaler Board and Main Board Shielding Formatter BD Main BD ...

Page 11: ... EFG H Item Male Connector on Main Board The key feature Figure A Blower Compose of Black Blue Red Wire and Gray tube 3 pin B Front IR Compose of Black Yellow Red Wire and Gray tube 3 pin C Photo Sensor BD Compose of Black White Red Wire Red Connector and Black tube 3 pin D Lamp Blower Compose of Black White Red Wire White Connector 3 pin E Lamp driver Black wire tube 5 pin ...

Page 12: ...disassemble the System Fan Module Note You should disassemble the System Fan Module first before the Engine Module disassembly Item Male Connector on Main Board The key feature Figure F G System Fan Compose of Red Yel low Black Wire 3 pin H Wire Power Board to Main Board Black wire tube 8 pin ...

Page 13: ...en to white screen Adjust the screws by using the rod on the engine module to readjust the image screw 1 should be adjusted first and then screw 2 Adjust until the yellowish or bluish parts disappeared 3 Abnormal image inspection It should not have any abnormal color at the rim of the image by estimating through the eyes Note To avoid over adjusting the rod After the operation please use the glue ...

Page 14: ...p Hours Full Use up or down buttons to select Exit then use left or right buttons to re write the lamp hours Full 3 Re write Lamp Hours ECO Use up or down buttons to select Factory reset then use left or right buttons to re write the lamp hour ECO 4 Choose Exit press Enter to exit Note left key decrease lamp hour right key increase lamp hour ...

Page 15: ...rmware Update v v v chapter 5 Color Wheel Index v v Chapter 4 3 1 7 OSD Reset v v v Chapter 4 5 2 Video Calibration v v v v Chapter 4 6 VGA Calibration v v v v Chapter 4 6 EDID v Chapter 6 Re write Lamp Hours Usage v Chapter 2 3 Video Performance v v v chapter 4 3 2 Restore Blower Speed v v v v Chapter 4 7 Optical Performance Measure v Chapter 4 3 1 2 5 Repair Action ...

Page 16: ...ssage Power LED Red Power LED Green Temp LED Red Lamp Led Orange Standby State input power cord Power on Warming Flashing Power on and Lamp lighting Power off Cooling Flashing Error Lamp failed Flashing Error Fan failed Flashing Flashing Error Over Temp Flashing Note Steady light No light ...

Page 17: ...tter Board Check Color Wheel b Power LED and Temp LED flash red Check Fan Check Main Board Check Photo Sensor Board c Power LED flashes red Temp LED light on red Check Thermal Switch Check Main Board 2 3D Image Abnormal Ensure the using 3D glasses is good and you must face the projection Ensure the CD in DVD is HQFS format or the graphic card from PC can support 3D format Ensure your standing dist...

Page 18: ...ite S Video and HDMI HDTV Source 720P 1080P 1080i Minolta CL 100 Quantum Data 802B or CHROMA2327 Color Video Signal Pattern Generator 4 2 Test Condition Circumstance brightness Dark room less than 2 lux Product must be warmed up for 3 minutes Screen size 60 inches diagonal Zone Definition Frame Figure Zone A Zone B Frame as green line Definition Active area Zone A Zone B ...

Page 19: ...ft arrow key to adjust the value to minimize video flicker Adjust Resync or Frequency Tracking H Position V Position to the inner screen Inspection item Eliminate visual wavy noise by Resync Frequency or Tracking selection Check if there is noise on the screen Horizontal and vertical position of the video should be adjustable to the screen frame Criteria If there is noise on the screen the product...

Page 20: ... IRE 100 Criteria The dead pixel is unacceptable on full white pat tern in zone A and no more than 2 dark pixels in zone B Adjacent pixels are unacceptable Ref Defect specification table 4 Bright Blemish Procedure Test equipment video generator Test signal analog Test Pattern gray 10 Inspection item Bright blemish check Criteria The bright blemish is unacceptable under gray 10 pattern in zone A an...

Page 21: ... 0 B 4 diameter 1 inch 6 Dark Blemish Dirty Blue 60 pattern A 0 B 4 diameter 1 inch 7 Bright pixel on frame Gray 10 pattern 1 6 Focus Test Procedure Test equipment video generator Test signal analog 1 Test Pattern full screen Inspection item Focus check Criteria From screen 1 8 M via visual to check the focus look at the entire screen focus shall be clear crisp and sharp over the entire surface of...

Page 22: ...ls should be sufficient and normal The unidentified color levels on both left and right sides should not over 4 color levels Gray level should not have abnormal color or heavy lines If color appears abnormal please get into service mode to do color wheel index adjustment 8 Optical Performance Inspection Condition Environment luminance 2 Lux Product must be warmed up for 5 minutes Distances from th...

Page 23: ...attern Full black pattern Use CL100 to measure brightness values of full white pattern P5 full black pattern B5 see image full white Follow Contrast formula to calculate contrast values Contrast Formula P5 B5 Note P5 Lux of center in full white pattern B5 Lux of center in full black pattern Criteria 1300 1 d Uniformity Procedure Full white pattern Use CL100 to measure brightness values of P1 P9 se...

Page 24: ...en Check the sound from speaker 4 3 3 Component Port Test Procedure Test equipment DVD player Test signal Ycbcr YPbPr Inspection item HDTV performance test Inspection Distance 1 4M 1 5M Criteria Check any abnormal color line distortion or any noise on the screen 4 3 4 HDMI Port Test Procedure Test equipment DVD Player with HDMI output Test signal 720p 1080p 1080i Inspection item HDMI performance t...

Page 25: ...hours Get into Burn In Mode Cycle setting is based on the defect symptoms ie If it is NFF the run in time is 4 hours You have to set the lamp on for 50 min and lamp off for 10 min for 4 cycles 4 3 5 3D Test Procedure Test equipment 1 DVD Player PS3 HQFS format CD or 2 PC with 3D Graphic card Test signal 1080p 24Hz HDMI 1 for 3D movie 720p 60HZ HDMI 2 for 3D game Inspection item 3D test Inspection ...

Page 26: ...re version All firmware version must be the latest version TB implementation Related TB must be implement Cosmetic Cosmetic can not be broken Logo Missing logo missing prints and blurry prints are unacceptable Lamp cover It should be locked in the correct place Zoom in out The function should work smoothly Keypad All keypad buttons must operate smoothly 2 OSD Reset After final QC step we have to e...

Page 27: ... Criteria If there is noise on the screen the product is consid ered as failure product The screen appears normal it shouldn t appear any abnormal condition such as lines and so on Check if the projection is same as monitor diplayed 2 Video Calibration Note After replacing main board or upgrading firmware the Video calibration should be done Procedure Test equipment video generator 1 Test signal 4...

Page 28: ...power button then hold Power button quickly then the Power LED light blue Temp LED and Lamp LED light red until the Power LED flash blue release the Power button 2 Wait a moment please get into service mode to check the Blower Factory RPM as Picture A shown Note If the Factory FAN RPM Value doesn t show in service mode please repeat the step again Make sure the Picture A ...

Page 29: ...l 5 Chapter 5 Firmware Upgrade Section 1 PW980 for FW Upgrade USB 5 1 1 Equipment Needed Software PW980 HD33_PW980 FW_xxx Hardware Projector Power Cord 42 50115G001 USB Cable mini USB to USB A 42 00284G001 PC or Laptop ...

Page 30: ...en Power button The PC will ask to install USB driver only for the first time Please refer to 5 1 3 for the installation of USB driver 5 1 3 Install USB Driver 1 Click on the Found New Hardware Wizard Select Install from a list or special location Advanced Click Next 2 Select Search for the best driver in these locations Choose Include this location in the search Click Browse ...

Page 31: ...33 Confidential 5 3 Select the Windowns Side usb driver then click OK 4 Wait for several seconds 5 Click Finish Note If Found New Hardware Wiszard picture appear again repeat step 2 to install USB Drivier ...

Page 32: ...the folder HD33_PW980 FW_xxx 2 Execute PW980 FlashUpgrader exe 3 Select HD33 inf for Flash File Select USB 2 0 for Connection Select Notify On Completion and Reset Target After Download Double click the u boot bin Click Flash button 4 The Downloading uImage will running ...

Page 33: ...When uImage downloads compeletly Downloading root cramfs will running automatically 6 When message Flash Completed appears click OK 7 Press Power off Left Left and Up button to get into service mode to check firmware version ...

Page 34: ...nfidential 5 HD33 Section 2 PA131 for FW Upgrade RS232 5 2 1 Equipment Needed Software PA131 HD33_PA131 FW_xxx Hardware Projector Power Cord 42 50115G001 RS232 Cable 9PIN to 9PIN 42 85H02G001 PC or Laptop ...

Page 35: ...mp LED lights on loosen Power button 3 Double click the FW folder HD33_PA131FW_xxx 4 Execute PA131 FlashUpgrader exe 5 Process Select PA131 for Chip Select Serial for Connection Select the COM Port which you are using Select 38400 for Baud Rate Select Notify On Completion and Reset Target After Download Choose PA131 inf for Flash File Click Flash button then press Power button ...

Page 36: ... completed 7 When FlasherBoot hex downloads completely Downloading Appcode hex will running automatically 8 When message Flash Completed appears click OK 9 Press Power off Left Left and Up button on remote controller to get into service mode to check firmware version ...

Page 37: ...3 8051 FW Upgrade 5 3 1 Equipment Needed Software N79A901R USB Setup _NLINK_en Manley USB Driver_NLINK xxx_8051_xx hex Hardware Projector Power cord 42 50115G001 USB Cable mini USB to USB A 42 00284G001 NLINK Fixture PC or Laptop ...

Page 38: ...o execute NLINK program 3 Choose the right type of MCU MCU Choose picture will appear on the screen select N79A901R Click OK 4 Program settings Ensure NLlNK Fixture and PC are securely connected the indicator lights on green and the state is Connect as blue square Select Brownout Level 3 8V as green square Select Internel RC 22 1184MHz as green square Click Erase then press Write W to execute 8051...

Page 39: ...HD33 Confidential 5 11 5 3 3 Check 8051 FW version 1 Restart the unit and enter the Service Mode Press Power off Left Left up 2 The firmware version will be shown as red circle on the screen ...

Page 40: ...r 6 EDID Upgrade 6 1 EDID Upgrade Procedure The upgrade procedure for VGA and HDMI ports please refer to common service manual chapter 6 Please use EDID 0 81 exe Program and Key in the serial number into the Unit No blank space ...

Page 41: ...HD33 Confidential Appendix A Exploded Image DC Note This chapter is only designed to show the exploded image of the projector For updated part numbers please refer to RSPL report ...

Page 42: ...L4 BRASS 11 70 8KZ07G001 MAINBOARD IOTOTALASSEMBLYWHITE 12 61 8EG14G001 EMISPRINGHD20 13 85 1A126G040 SCREWPANMECHM2 6 4Ni 14 49 8KZ02G011 SUNON8525AXIALFANLOWROTATINGSPEED WITHLINELENGTH150MM RoHS2 0 V 15 85 0A323G030 SCREWP FMECHM3 L3BLACK 16 85 3A126G060 NEWSCREWM 2 6D 2 48 2 58L 6 0束尾2 0MM 17 61 8KZ08G001 MAINBOARDTOPSHEETMETAL0 3T 18 61 8KZ01G001 SIDEMESHHD33 19 85 0A123G040 SCREWP FMECHM3 4N...

Page 43: ...00061G001 LOCKSCREWPANMECHM3 8 5 3 5Ni 27 51 8KZ24G001 LEFTVENTHD33 28 51 8KZ18G001 TOPIRMYLARBLACK 29 51 8KZ20G001 TOPPROTECTIVEFILMHD33 30 61 8KZ03G001 DUAL8525FANSHIELDINGHD33 31 70 8KZ20G001 FOCUSRINGASSEMBLYWHITE 32 52 8KZ08G001 FANSHIELDINGTOPSPONGEHD33 ...

Page 44: ...HD33 Confidential Assy Main Board ...

Page 45: ...MATTERBOARDFORHD33PROJECT OR V 2 80 8KZ01G001 PCBAMAINBOARDFORHD33PROJECTOR V 3 61 00074G001 HEXSCREWL 18 4M3 M3Ni5100MP 4 85 1F123G060 SCREWPANMECHW SFM3 6NiGREEN 5 52 8KZ04G001 FORMATTERLIGHTLEAKSPONGE 6 52 8KZ05G001 SCALARBDLIGHTLEAKSPONGE 7 51 8KZ15G001 MAINBDBOTTOMMYLAR ...

Page 46: ...HD33 Confidential Assy Engine Module ...

Page 47: ...8 5x14 5x0 5mm 9 61 8FC02G001 DMDLIGHTMASKEH1020 10 61 88611G001 DMDSCREWIvy10X 11 51 00210G001 DMDSCREWWASHERA39 12 48 8EG01G001 DMD1920 1080PIXEL0 65 1080P2xLVDSDC2TYPEA V 13 11 009F0G007 CNNTF203PFOR720PLGADMDSOCKETPE020323 03040 10 FOXCO 15 51 81540G001 TAPE3MJ35017 60mm 16 23 8AH20G001 CONDENSER1FORA15W 17 23 8AH20G002 CONDENSER2FORA15W 18 51 8EG34G001 DMDINSULATIONSLICEHD20 19 61 8AH08G001 D...

Page 48: ...5927G001 DMDSHOULDERSCREWSB21 27 61 8EG15G001 STEPSCREWM2x4FORYM40LENS 28 61 8KZ05G001 DMDBOARDBRACKETHD33 29 51 8EG33G001 3MTAPEA15WENGINEBASEHD20 30 52 8KZ07G001 ENGINETOPSPONGEHD33 30 61 8KZ03G001 DUAL8525FANSHIELDINGHD33 31 70 8KZ20G001 FOCUSRINGASSEMBLYWHITE 32 52 8KZ08G001 FANSHIELDINGTOPSPONGEHD33 ...

Page 49: ...1 ASSY IO COVER MODULE 8KZ WHITE SERVICE V 1 75 8KZ02G001 IOCOVERASSYWHITEHD33 2 80 8KZ03G001 PCBAPOWERLEDBDFORHD33PROJECTOR V 3 85 0A123G040 SCREWP FMECHM3 4Ni 4 35 8KZ01G001 REARIOLABELHD33WHITE 5 42 005E0G002 WIREPOWERBOARDTOMAINBOARD150MM Assy IO Cover Module 1 ...

Page 50: ...0 Assy Top Cover Module Item PN Description Parts Supply 1 75 8KZ01G001 TOPCOVERWHITEHD33 V 2 51 8EG09G001 ZOOMRINGHD20 3 51 8KZ19G001 ZOOMRINGTEFLONHD33 4 85 1A123G050 SCREWPANMECHM3 5Ni 5 51 8KZ12G001 ZOOMRINGCOVERBLACK ...

Page 51: ...HD33 Confidential 11 Assy Lamp Module ...

Page 52: ...UCTHD33 9 61 8EE18H002 LAMPDUCTBACKFOILALADC 12H7530 10 61 8EE19H001 LAMPDUCTCAPH7530 11 52 8KZ02G001 LAMPLIGHTCUTRUBBERHD33 12 61 00018G003 LOCKSCREWPANMECHM3 8 5 3 5BLACK 1018 HEATTREATMENT 13 61 80L06G001 UVIRSPRINGPLATESUS30180L 14 61 86808G002 LAMPCHANGERHANDLESUS3041 6dDP725F ORCPC 15 23 88N10G001 UV IR24 25 2mm 5 5mmcut _AddDotinkmark Oerlikon 16 42 0043GG001 W A 2P 22MALE6KV200度 C140mmFORL...

Page 53: ...G06G001 D42COLORWHEELHOLDERHD20 3 61 8EG07G001 D42CWHOLDERCOVERHD20 4 52 83615G001 COLORWHEELDISCRUBBER EzPro755 5 61 83628G001 COLORWHEELSHOULDERSCREW EzPro755 6 51 82Y29G001 PCBAPHOTOSENSORBOARDFORHD20 7 80 8LP04G001 PCBAPHOTOSENSORBOARDFORES526XPROJE COR V 8 51 8HH08G001 PHOTOSENSORCOVERHOLDERPCLN 2520AUF65 9 54 8HH01G001 PHOTOSENSORCOVERGLASSUF65 10 85 1A526G060 SCREWPANMECHM2 6 6NiNYLOK ...

Page 54: ...HD33 Confidential 14 Assy Bottom Cover Module ...

Page 55: ...1 EMI GASKET W5 H1 0 L155mm PD527 10 51 8KZ21G001 LVPS MYLAR HD33 11 75 8FB01GP01 ASSY 280W LVPS FOR EX762 V 12 85 1C224G051 SCREW PAN MECHM4 5 COLORW TOOTH WASHERCr3 13 61 88T19G011 8KZ AC INLET BRACKET 14 85 1F123G060 SCREW PAN MECHW SFM3 6NiGREEN 15 70 8KZ14G001 ASSY LIMIT SWITCH HD33 16 85 WA126G050 SCREW PAN TAPM2 6 5Ni 17 85 3A122G040 SCREWCAPMECHM2 4Ni 18 51 8KZ24G001 LEFT VENT HD33 19 51 8...

Page 56: ...HD33 Confidential 16 AK ...

Page 57: ...POWERCORD1830mmSP30 IS14 BC PUPIXY01 3 35 82001G111 AK LABEL 3 3 BLANK 4 36 00024G001 WARRANTYCARDUSFORLPPSERIES 1YEAR 5 36 8KZ01G001 USER SGUIDEMULTILINGUAL CD HD33 V 6 36 00040G011 INSTRUCTIONCARD OPTOMA BEFORERETURNFORPICO 7 45 8KZ01G001 REMOTECONTROLFORHD33PROJECTOR V SP 8KZ02GC01 REMOTECONTROLFORHD33 V 8 46 80S01G101 BATTERY 71 5VNOVACELL 9 51 00027G003 PEBAGZIPPER33cm 25cmSIZEGREENFOROP TOMA...

Page 58: ...Z Project Code 3 1 Last number of the manufacture year ex 2011 1 4 15 week of the manufacture year ex the fifteenth week of the year 15 5 AAAAA not defined 6 C Manufacture factory 7 0001 Serial Code EX Q8KZ115AAAAAC0001 This label Q8KZ115AAAAAC0001 represents the serial number for HD33 It is produced at CPC on fifteenth of 2011 Its serial code is 0001 ...

Page 59: ...HD33 Confidential II II PCBA Code Definition PCBA Code for Projector A B XXXXXXXXXX C XXX EEEE 1 2 3 4 5 6 1 ID 2 Vendor Code 3 P N 4 Revision 5 Date Code 6 S N ...